Plaster wall surface



Aug. 12, 1930. c. A. upson 1,772,648

PLAsTER WALL SURFACE Filed Jan.V 17. 1929 f mvENToR -4 Cle Wmo@ which can be rapidl Patented Aug. 1 2, 1930 UNITED STATES PATENT OFFICE CHARLES A. UPSON, OF LOGKPORT, NEW YORK, ASSIGNOB TO THE UPSON QOMPANY, OF

LOCKPORT, NEW YORK, A. CORPORATION OF NEW YORK y BLASTER WALL summer:

Application led January 17, 1929. Serial No. 333,150.A

My present invention relates to building material, and more particularly to plaster wall surfaces and a method of making the same whether the plaster is applied after the 5 rest of the wall is in place, or whether it is desired to lirst apply the plaster as an outer iinishing surface to a ready-to-apply wallboard, and the invention has for its object to provide an improved structure of this character and cheaply produced; which will have higlier wearing and insulating qualities, and in which, particularly, theV plaster surface will be intimately and effectively loclied to the supporting body.

To these and other ends the invention resides in certain improvements and combinations of parts, all as will be hereinafter more fully described, the novel features being pointed out in the claims at the end of this specification.

In the drawings:

Fig. 1 is a perspective view of a fragment of a wallboard provided with a plaster surface constructed in accordance with and illustrating one embodiment of my invention, several elements com osing the same being shown cut away from each other in diHerent parallel planes to better illustrate the composite makup; ,a

Fig. 2 is a section through the board shown in Fig. 1;

Fig. 3 is a view similar to Fig. 1 of a modified form of board, and l Fig. 4 is a section through the board shown in Fig. 3.

Similar reference numerals throughout the several views indicate the same parts.

A preferred form of my new wall surface or wall board and the methodof producing the same involves the use of the invention disv.closed in the United States patents to Howard F. Weiss et alyNo. 1,628,206, dated May 10, 1927, entitled Molded product and process for its manufacture, and Kemper f Slidell, No. 1,655,714, dated January 10, 1928, A and entitled Machine and method for makf ing wallboard to which reference is suggested. It will be understood however, as indicated by the claims, that my invention is not v 5 limited to the operation, materials, and construction therein disclosed. Briefly these patents explain the making of a wallboard for building and similar purposes by a method in which a plastic intumescent body of material having as its principal ingredients a solution of silicate of soda mixed with an inorganic fller such as dolomitic limestone ground to a powdered iineness is introduced between two heavy paper liners and then passed between the confining walls of op- .posed heated platens, whereby the material is puffed into a highly cellular sheet with smooth flat paper surfaces. When the sheet is hardened by further heat treatments and drying it is transformed into a rigid coherent mass having great insulating qualities and the cells of which are larger or smaller according to` the proportion of the component elements emplo ed.

In the practlce of my present invention, I prefer to use this method arranging to produce a relatively large cellular structure in theV intumescentinorganic material, but in one embodiment of my invention, I use only one of the paper liners described in Patent No. 1,655,474, aforesaid, and referring to Figs. 1 and 2 in which this embodiment is illustrated 1 indicates the heavy paper liner, and 2 the inturnescent body which has been caused to adhere thereto firmly by the puffing process. It will be seen from an inspection of Fig. 1 that the outer face of the body 2 opposite to that which is attached to the paper liner or backing 1 has a roughened irregular pitted surface represented by the cells which are only partly formed in the body of the material and open on that surface. In the further practice of my invention I apply Yes to the surface a layer 3 of ordinary plaster l in the plastic state by smearing it over and working it into the same giving the exterior to the wall may receive the plaster coating or surfacing 3 as before.

Figs. 3 and 4, as before stated, illustrate another method of producing the article which is somewhat better adapted to the process of the patents referred to if this is to be utilized in making up the cellular body element. In drawing the backing liner 1 and the body 2 through the heated platen diiiculties may arise owing to a tendency on the part of the intumescent plastic 2 to stick to the heated platens. To avoid this I may use, in addition to the heavy liner 1 a very light tissue-like liner 4 on the opposite or outer face, the same being com osed of the very thinnest paper that can be ed to the machine.'

When, however, the plaster bod 3 is applied as before to furnish the desire surface, this tissue 4 becomes saturated by the wet plaster and is destroyed as a liner permitting the plaster in its plastic state to permeate the cells and lock into the same as before.

It will be understood that my reference to the two existing United States patents aforesaid is merely an illustration of one manner of accomplishing the desired results of the resent invention in the production of a suita le cellular body on a backing to take the laster surface, and it is to be understood furt er that, in the broad aspects of m present invention, this body element may produced in other ways.

I claim as my invention:u

1. A method of making plaster wall surfaces which embodies applying a hard adhesive cellular mineral composition to a rel- `atively heav paper liner at the same time applying a t in tlssue-like liner to the opposite side of the cellular body and then app i ing a coating of plaster in a plastic` state to the outer tissue and working it therethrough so that it permeates the cells and is locked to the cellular composition, the tissue liner beilg softened and destroyed as such by the wet p aster.

2. A method of makingplaster wall surfaces which embodies introducing, a plastic intumescent bod containing silicate of soda and a mineral ler as its main ingredients between a relatively heavy backing sheet or liner and a relatively thin and'tissue-like liner, pulling -the intumescent body by heat while suitably confined 'to form a cellular body adherin to the liners, hardening the same, and app ying a coating of plastic plaster to the outer tissue liner and working it ren throu h the same so that it rmeates' the outer cel s of the cellular bo y and is thereby locked thereto, the tissue liner being softened and destroyed as such by the wet plaster.

CHARLES A. UPsoN. l 

